Mixing valve

ABSTRACT

The present invention relates generally to fluid control valves and, more particularly, to a mixing valve for use within a faucet.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to fluid control valves and,more particularly, to a mixing valve for use within a faucet.

Single-handle water faucet control valves are well known in the art andhave been offered with different mechanical structures for controllingthe available directions of travel, the ranges of motion, and the typeor style of motion for the handle. One such known style of control valveincludes a handle that is moved in a generally sideways (left-to-rightand right-to-left) direction in order to adjust the mix of hot and coldwater for a desired temperature. With this style of water faucet valvecontrol arrangement, the handle is typically moved in an upward orforward direction, away from the user, to increase the flow rate and thevolume of water delivered. The handle is typically moved in a downwardor rearward direction, toward the user, in order to reduce the flow rateand volume of water, or to completely shut off the flow of waterdelivered from the faucet.

Known single-handled control valves are often referred to as having ajoy stick control handle due to the single-handle construction and themanner in which the handle may be moved. The directions and ranges ofmotion are controlled by the internal structure of the valve mechanismand by the selection and arrangement of the component parts. It isfurther known to provide a water faucet control valve that isconstructed and arranged to independently control the temperature andthe flow rate of the water delivered to a use location by asingle-handle or control lever. Illustrative examples of single-handledfaucet control valves are described in U.S. Pat. No. 6,920,899, and U.S.patent application Ser. No. 11/444,228, filed May 31, 2006, thedisclosures of which are expressly incorporated by reference herein.

One illustrative embodiment of the present invention includes a valveassembly for controlling water flow in a faucet, the valve assemblyincluding a valve body having hot and cold water inlets and an outlet. Alower disc includes first, second, and third ports corresponding to thehot and cold water inlets and the outlet, and is supported by the valvebody. An upper disc includes upper and lower surfaces, the lower surfacebeing positioned in engagement with the lower disc and including aperipheral channel for selective communication with the first, second,and third ports.

Another illustrative embodiment of the present invention includes avalve assembly for controlling water flow in a faucet, the valveassembly including a valve body having an inlet and an outlet. A valvemechanism is configured to selectively control the flow of the waterfrom the inlet to the outlet, the valve mechanism being positioned inthe valve body. An upper housing includes an interior cavity. A ballincludes a stem and two extensions extending laterally from the ball.The ball is adapted to be positioned in the interior cavity of the upperhousing and to move through a range of motion. A coupling member isconfigured to couple to the upper housing to secure the ball, andincludes a cavity configured to cooperate with the ball and a pluralityof tabs extending toward the upper housing. The tabs are positionedadjacent to the extensions of the ball and defining a continuous glidesurface along the range of motion of the ball.

A further illustrative embodiment of the present invention includes avalve assembly for controlling water flow in a faucet, the valveassembly including a valve body having an inlet and an outlet. Aplurality of discs are configured to control the flow of water throughthe valve body from the inlet to the outlet. An upper housing includes abody defining an interior cavity and a flexible arcuate rib extendingfrom the body into the cavity. A coupling member is configured to coupleto the upper housing. A ball includes a stem and is positioned betweenthe upper housing and the coupling member in the interior cavity inengagement with the flexible arcuate rib. The ball is configured toactuate at least one of the plurality of discs to selectively controlthe flow of water through the valve assembly.

Another illustrative embodiment of the present invention includes avalve assembly for controlling water flow in a faucet, the valveassembly including a valve body including an interior cavity. Hot andcold water inlets and an outlet are in communication with the interiorcavity. The valve assembly further includes an upper housing including avalve actuator, a lower housing, and a lower disc positioned in thelower housing. The lower disc includes a plurality of portscorresponding to the hot and cold inlets and the outlet. An upper discis positioned above the lower disc and includes upper and lowersurfaces, the lower surface including a first channel configured tointeract with the plurality of ports, and the upper surface including anaperture extending therethrough and at least one depression. A carrieris positioned above the upper disc and is configured to cooperate withthe upper disc such that the aperture causes water to exert pressureagainst the upper surface of the upper disc to create a pressurereversing hydrobalance. The carrier is adapted to interact with thevalve actuator, and a bonnet nut is adapted to couple to the valve body.The bonnet nut is configured to secure the upper and lower housings inthe interior cavity of the valve body.

A further illustrative embodiment of the present invention includes avalve assembly for controlling water flow in a faucet, the valveassembly having a valve body having an interior cavity and an inlet andan outlet in communication with the interior cavity. A valve mechanismincludes an upper housing having a valve actuator and a lower housingcoupled to the upper housing. The upper housing includes an outer flangepositioned above the valve body, and the lower housing includes a valveactuated by the valve actuator. The valve mechanism is positioned withinthe interior cavity of the valve body, and a bonnet nut is adapted tocouple to the valve body and to secure the valve mechanism in theinterior cavity of the valve body. The bonnet nut includes an interiorridge adapted to contact the outer flange of the upper housing toprovide a separation between the bonnet nut and the valve body.

Another illustrative embodiment of the present invention includes avalve assembly for controlling water flow in a faucet, the valveassembly including a valve body having an interior cavity, hot and coldwater inlets in communication with the interior cavity, and a wateroutlet in communication with the interior cavity. A valve mechanismincludes an upper housing having a valve actuator and a lower housingcoupled to the upper housing. The lower housing includes an upper discand a lower disc, the lower disc including a plurality of portscooperating with the hot and cold water inlets and the water outlet. Theupper disc is configured to be actuated by the valve actuator toselectively allow water flow in the faucet. The valve mechanism ispositioned within the interior cavity of the valve body. A singlesealing surface is positioned in the interior cavity of the valve bodybetween the valve body and the valve mechanism, the sealing surfacebeing in contact with the lower disc.

Additional features and advantages of the present invention will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of the illustrative embodiment exemplifying thebest mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the drawings particularly refers to theaccompanying figures in which:

FIG. 1 is a perspective view of a faucet including an illustrativeembodiment valve assembly shown in phantom;

FIG. 2 is a perspective view of the illustrative embodiment valveassembly of FIG. 1;

FIG. 3 is an exploded perspective view of the valve assembly shown inFIG. 2;

FIG. 4 is an exploded upper perspective view of internal components ofthe valve assembly shown in FIGS. 2 and 3;

FIG. 5 is an exploded bottom perspective view of internal components ofthe valve assembly shown in FIG. 4;

FIG. 6 is a bottom perspective view of the upper housing of the valveassembly shown in FIGS. 2-5;

FIG. 7 is a cross-sectional view of the upper housing shown in FIG. 6;

FIG. 8 is a bottom plan view of the upper housing shown in FIGS. 6 and7;

FIG. 9 is an exploded perspective view of the stem assembly and thecoupling member of the valve assembly shown in FIGS. 2-5;

FIG. 10 is a cross-sectional view of the valve assembly taken alonglines 10-10 of FIG. 2 with the valve assembly in the partially openorientation;

FIG. 11 is a partial top plan view of the valve assembly shown in FIG.10, with internal components of the valve assembly shown in phantom;

FIG. 12 is a cross-sectional view of the upper and lower discs of thevalve assembly taken along lines 12-12 of FIG. 10, with the valveassembly being oriented in the partially open orientation;

FIG. 13 is a cross-sectional view of the valve assembly similar to FIG.10, with the valve assembly shown in the fully-opened orientation;

FIG. 14 is a partial top plan view of the valve assembly shown in FIG.13, with internal components shown in phantom;

FIG. 15 is a cross-sectional view of the upper and lower discs of thevalve assembly taken along lines 15-15 of FIG. 13, with the valveassembly being oriented in the fully-open orientation;

FIG. 16 is a cross-sectional view of the valve assembly similar to FIG.10, with the valve assembly shown in the fully-closed orientation;

FIG. 17 is a partial top plan view of the valve assembly shown in FIG.16, with internal components shown in phantom;

FIG. 18 is a cross-sectional view of the upper and lower discs of thevalve assembly taken along lines 18-18 of FIG. 16, with the valveassembly being oriented in the fully-closed orientation;

FIG. 19 is a partial top plan view of the valve assembly shown in theprevious figures with internal components being shown in phantom, thevalve assembly being oriented to allow only cold water flow;

FIG. 20 is a cross-sectional view of the upper and lower discs of thevalve assembly shown in FIG. 19, with the valve assembly being orientedto allow only cold water flow;

FIG. 21 is a partial top plan view of the valve assembly shown in theprevious figures with internal components being shown in phantom, thevalve assembly is oriented to allow only hot water flow;

FIG. 22 is a cross-sectional view of the upper and lower discs of thevalve assembly shown in FIG. 21 with the valve assembly being orientedto allow only hot water flow;

FIG. 23 is an exploded perspective view of another illustrativeembodiment valve assembly;

FIG. 24 is a cross-sectional view of the valve assembly shown in FIG.23;

FIG. 25 is an exploded bottom perspective view of the internalcomponents of the valve assembly shown in FIGS. 23 and 24;

FIG. 26 is an exploded upper assembly view of the internal components ofthe valve assembly shown in FIGS. 23-25;

FIG. 27 is a partial perspective view of a further illustrativeembodiment valve assembly, with the valve body and the bonnet nutremoved for clarity;

FIG. 28 is an exploded perspective view of the valve assembly of FIG.27;

FIG. 29 is a top plan view of the valve assembly of FIG. 27, with thetemperature limiting member shown in a low limit position and the stemshown in a fully-closed position;

FIG. 30 is a perspective view of the valve assembly of FIG. 27, with theupper housing removed for clarity;

FIG. 31 is a cross-sectional view taken along line 31-31 of FIG. 29;

FIG. 32 is a cross-sectional view taken along line 32-32 of FIG. 29;

FIG. 33 is a bottom plan view of the upper housing of the valve assemblyof FIG. 27;

FIG. 34 is a bottom perspective view of the temperature limiting memberof the valve assembly of FIG. 27;

FIG. 35A is a side elevational view of the valve assembly of FIG. 29,with the temperature limiting member shown in a low limit position andthe stem shown in a fully-closed position;

FIG. 35B is a side elevational view similar to FIG. 35A, with the stemshown in an open hot limit position;

FIG. 35C is a side elevational view similar to FIG. 35A, with the stemshown in an open cold limit position;

FIG. 36 is a top plan view of the valve assembly of FIG. 27, with thetemperature limiting member shown in a high limit position and the stemshown in a fully-closed position;

FIG. 37 is a perspective view of the valve assembly of FIG. 27, with theupper housing removed for clarity;

FIG. 38A is a side elevational view of the valve assembly of FIG. 36,with the temperature limiting member shown in a high limit position andthe stem shown in a fully-closed position;

FIG. 38B is a side elevational view similar to FIG. 38A, with the stemshown in an open mixed water position;

FIG. 38C is a side elevational view similar to FIG. 38A, with the stemshown in an open hot limit position; and

FIG. 38D is a side elevational view similar to FIG. 38A, with the stemshown in an open cold limit position.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to beexhaustive or to limit the invention to precise forms disclosed. Rather,the embodiment selected for description have been chosen to enable oneskilled in the art to practice the invention. Although the disclosure isdescribed in connection with water, it should be understood thatadditional types of fluids may be substituted therefor.

Referring initially to FIG. 1, a faucet assembly 10, having a hot watersupply conduit 20 and a cold water supply conduit 22, is shown. Faucetassembly 10 includes a delivery spout 16, an aerator 18, a base 12, ahandle 14, and a valve assembly 24. Valve assembly 24 includes a stem 26that may be actuated by handle 14 to selectively allow variabletemperature and flow rate of water to be supplied to spout 16 fromsupply conduits 20 and 22.

Referring now to FIG. 2, valve assembly 24 is shown. Valve assembly 24includes holder, illustratively valve body 34, and bonnet nut 28. Inthis embodiment, valve body 34 and bonnet nut 28 are constructed ofbrass, however any suitable material may be used. Valve body 34 extendsalong a longitudinal axis 33 (FIG. 3) and includes outlet bore 36 whichmay be operably coupled to an outlet supply line which, in turn, may becoupled to a spout 16, such as the one shown in FIG. 1, or any othersuitable fluid delivery device, such as a hand sprayer. Bonnet nut 28includes internal threads 39 that correspond to external threads 37 ofvalve body 34 (FIG. 10). Bonnet nut 28 also includes grooves 30positioned to accept a wrench (not shown) to secure bonnet nut 28 tovalve body 34. Bonnet nut 28 further includes a central aperture 32 intowhich an upper housing 38 extends. Stem 26 extends through aperture 46of upper housing 38. In this embodiment, aperture 46 is substantiallydiamond-shaped to limit the movement of stem 26, however any suitablyshaped aperture may be used.

Referring now to FIGS. 3-9, the internal components of valve assembly 24are shown. Valve assembly 24 includes valve body 34, lower housing 80,lower disc or first sealing member 72, upper disc or second sealingmember 68, carrier 62, coupling member 50, stem assembly 23, upperhousing 38, and bonnet nut 28. The exterior portion of upper housing 38includes a shoulder portion 48, a flange 40, extensions 44, and tabs 42.Flange 40 extends circumferentially around portions of upper housing 38,and is positioned between bonnet nut 28 and valve body 34 when bonnetnut 28 is threaded onto valve assembly 34. As such, bonnet nut 28provides a compressive force on flange 40 and upper housing 38. Flange40 also provides a barrier between bonnet nut 28 and valve body 34 toprevent corrosion and seizing therebetween. In certain embodiments,shoulder portion 48 may be configured to contact interior ridge 31 ofbonnet nut 28 to compress upper housing 38 when valve assembly 24 isassembled. Illustratively, upper housing 38 is constructed of plastic,however any other suitable materials may be used to construct thecomponents.

Valve assembly 24 also includes stem assembly 23 which includes ball 25,stem 26, lateral extensions 27 a, 27 b, and longitudinal extension orknuckle 29. In the illustrative embodiment, a first angle α definedbetween the longitudinal axis of stem 26 and an axis defined byextension 27 a is greater than ninety degrees, and a second angle βdefined between the longitudinal axis of stem 26 and the axis defined byextension 27 b is less than ninety degrees (FIG. 10). However, it shouldbe appreciated that stem 26 may be positioned at any suitable anglerelative to extensions 27 a and 27 b. Stem assembly 23 is positionedbetween upper housing 38 and coupling member 50 so that stem 26 extendsthrough aperture 46 in upper housing 38 and ball 25 is positioned ininterior cavity 53 of upper housing 38 (FIG. 6). Referring now to FIGS.6-8, upper housing 38 includes interior cavity 53, opposing arcuateflexible ribs 55, and opposing relief portions 57. Arcuate flexible ribs55 extend from interior cavity 53 and provide a compressive force onball 25 when valve assembly 24 is fully assembled.

Referring now to FIGS. 3 and 9, coupling member 50 includescircumferentially spaced projections 52 and apertures 60 positionedradially outwardly from cavity 54. Aperture 51 is positioned at thebottom of cavity 54 which is formed by arcuate surface 59.Illustratively, aperture 51 is of a substantially triangular shape.Apertures 60 are positioned to accept tabs 42 of upper housing 38 tocouple stem assembly 23 between upper housing 38 and coupling member 50.Tabs 42 each include a latch or lip 43 configured to cooperate with anotch 41 of each aperture 60 for locking engagement therebetween (FIGS.6 and 10). Projections 52 are positioned to secure coupling member 50 tolower housing 80 (as shown in FIG. 3), which is discussed below.

Coupling member 50 also includes a first pair of tabs 56 and a secondpair of tabs 58 that extend upwardly from cavity 54. When assembled,ball 25 is positioned in cavity 54 and extensions 27 a and 27 b arepositioned between first pair of tabs 56 and second pair of tabs 58,respectively, as shown in FIG. 9. First and second pairs of tabs 56 and58 are positioned adjacent to extensions 27 a and 27 b of stem assembly23 and define opposing continuous glide surfaces 61 a and 61 b along therange of motion of ball 25 of stem assembly 23. In operation, extensions27 a and 27 b glide along the surfaces 61 a and 61 b, respectively, oftabs 56 and 58 during movement of stem 26 to operate valve assembly 24.

Referring now to FIG. 6-9, when assembled, relief portions 57 of upperhousing 38 accept first and second pairs of tabs 56 and 58 of couplingnumber 50. As shown in FIG. 3, stem assembly 23 is positioned betweenupper housing 38 and coupling number 50. As discussed above, extensions27 a and 27 b of stem assembly 23 are positioned between first pair oftabs 56 and second pair of tabs 58 of coupling member 50. Stem 26extends through aperture 46 in upper housing 38. First pair of tabs 56and second pair of tabs 58 are positioned in relief portions 57 of upperhousing 38. An upper portion of ball 25 of stem assembly 23 is contactedby arcuate flexible ribs 55 of upper housing 38, and a lower portion ofball 25 is contacted by arcuate surface 59 of coupling member 50. Tabs42 interact or “snap fit” within openings 60 in coupling member 50 tosecure stem assembly 23 between upper housing 38 and coupling member 50.Longitudinal projection 29 extends through aperture 51 in couplingnumber 50.

Referring now to FIGS. 3-5, longitudinal extension 29 of stem assembly23 extends into recess or aperture 64 of carrier 62. Carrier 62 includesplurality of projections 65, plurality of arcuate openings 67, andgroove 63 configured to accept a conventional O-ring 66. Plurality ofprojections 65 of carrier 62 interact with depressions 69 in the uppersurface 68 a of upper disc 68. O-ring 66 contacts the upper surface 68 aof upper disc 68 and forms a circumferential seal between carrier 62 andthe upper surface 68 a of upper disc 68. Upper disc 68 includes anaperture 70 extending therethrough to provide fluid communicationbetween a lower surface 68 b of upper disc 68 and the lower surface 62 bof carrier 62.

As shown in FIG. 3, upper disc 68 is positioned on top of lower disc 72in valve assembly 24. The lower surface 68 b of upper disc 68 is shownin more detail in FIG. 5. Upper disc 68 is positioned on top of lowerdisc 72 in valve assembly 24 to control the mixing of hot and cold waterand the flowrate of water through valve assembly 24. As further detailedbelow in connection with FIGS. 10-22, the upper disc 68 isillustratively supported for movement relative to lower disc 72, whereintranslational movement in a first direction controls flow rate andtranslational movement in a second perpendicular direction controls thetemperature (i.e., mixing of hot and cold water). Lower disc 72 includesa pair of notches 74 configured to interact with portions 86 of lowerhousing 80 to orient and prevent rotation of lower disc 72 relative tolower housing 80. In this embodiment, both upper and lower discs 68 and72 are constructed of a ceramic material, however any suitable materialmay be used, such as stainless steel.

Referring further to FIGS. 4 and 5, the upper and lower surfaces ofcarrier 62, upper disc 68, lower disc 72, lower housing 80 and valvebody 34 are shown. Lower disc 72 includes hot and cold water inlet ports76 a and 76 b and outlet port 78 illustratively extending between upperand lower surfaces 72 a and 72 b, respectively. Each inlet port 76 a and76 b includes an inner edge 83 and an outer control edge 85 positionedlaterally, illustratively radially outwardly, from the inner edge 83.The lower surface 68 b of the upper disc 68 defines a laterallyextending first sealing surface 87 and the upper surface 72 a of thelower disc 72 defines a laterally extending second sealing surface 89sealingly engaging the first sealing surface 87. The lower surface 68bof upper disc 68 includes a circumferentially extending channel 77defined between a central portion 73, having an inner channel edge 73 a,and an annular outer channel edge or lip 79. Central portion 73 includesV-shaped section 71 conforming to a projection 75 of annular lip 79.Channel 77 and central portion 73 provide selective communicationbetween hot and cold water inlet ports 76a and 76b and outlet port 78when upper disc 68 is moved relative to lower disc 72. The interactionbetween upper disc 68 and lower disc 72 during operation of valveassembly 24 is described in more detail in connection with FIGS. 10-22.In the illustrative embodiment, carrier 62 and upper disc 68 havesubstantially smaller diameters than lower disc 72 and lower housing 80to enable upper disc 68 to be moved relative to lower disc 72, as shownin FIG. 10.

Referring now to FIGS. 3 and 4, lower disc 72 is positioned in lowerhousing 80. Opening 81 of lower housing 80 is sized to allow seals 90,which are positioned in hot and cold water inlet bores 91 a and 91 b andoutlet bore 95, to seal against the lower surface 72 b of lower disc 72.Seals 90 a and 90 b form a seal around hot and cold water inlet ports 76a and 76 b on lower surface 72 b of lower disc 72, and seal 90 c forms aseal around outlet port 78 on the lower surface 72 b of lower disc 72.Collectively, seals 90 form a single sealing surface between valve body34 and internal components of valve assembly 24. Hot and cold inletbores 91 a and 91 b are illustratively connected to hot and cold watersupply conduits 20 and 22, respectively. Outlet bore 95 may be connectedto an outlet supply line to, for example, spout 16 of faucet 10, such asthe one shown in FIG. 1. Hot and cold water inlet ports 76 a and 76 band outlet port 78 of lower disc 72 are positioned directly above, andin fluid communication with, hot and cold water inlet bores 91 a and 91b and outlet bore 95 of valve body 34, respectively.

Referring now to FIGS. 3-5, lower housing 80 includes a pair of upwardlyextending extensions 82 including apertures 84 configured to acceptprojections 52 of coupling member 50 to secure coupling member 50 tolower housing 80. Lower housing 80 also includes a pair of lowerprojections 88 configured to be positioned in bores 93 in the lowerinterior surface of valve body 34 to prevent rotation of lower housing80 relative to valve body 34. As illustrated, seals 90 a, 90 b, and 90 care positioned in bores 91 a, 91 b, and 95 in the lower interior surfaceof valve assembly 90 to prevent water leakage between bores 91 a, 91 b,and 95 in valve body 34 and the lower surface 72 b of lower disc 72. Inthis illustrative embodiment, valves 90 are constructed of rubber andprovide a biasing force between the lower surface of valve body 34 andlower disc 72. Seals 90 may be of the type detailed on U.S. patentapplication Ser. No. 11/444,228, filed May 31, 2006, which has beenexpressly incorporated by reference herein. Valve body 34 includes apair of notches 35 configured to accept tabs 44 extending from upperhousing 38 to prevent rotation of upper housing 38 relative to valvebody 34. Valve body 34 also includes external threads 37 configured tointeract with internal threads 39 (FIG. 10) on the interior surface ofbonnet nut 28 to secure bonnet nut 28 to valve body 34.

Referring further to FIG. 5, when valve assembly 24 is coupled to hotand cold water supply conduits 20 and 22, a pressure reducinghydrobalance is created between carrier 62 and upper disc 68. Aperture70 in upper disc 68 allows water from channel 77 to flow between carrier62 and the upper surface 68 a of upper disc 68. Openings 67 of carrier62 may also be supplied with water supplied from aperture 70. In theillustrative embodiment, the area of upper surface 68 a of upper disc 68defined within O-ring 66, which is positioned in groove 63 of carrier62, is greater than the collective cross-sectional area of seals 90 aand 90 b, which are positioned between the lower surface of lower disc72 and valve body 34. In other words, the water pressure between carrier62 and upper disc 68 has a greater surface area on which to act thanthat of water pressure acting on seals 90 a and 90 b. Therefore, thewater pressure creates a net downward force on the upper surface 68 a ofupper disc 68 to minimize any leakage between upper disc 68 and lowerdisc 72.

Referring now to FIG. 10, a cross-sectional view of valve assembly 24 isshown. As discussed above, interior ridge 31 of bonnet nut 28 contactsshoulder portion 48 of 48 of upper housing 38 to provide a compressiveforce on upper housing 38. Additionally, flange 40 is positioned betweenbonnet nut 28 and valve body 34 to prevent corrosion and provide abiasing force between bonnet nut 28 and valve body 34. Tabs 42 of upperhousing 38 interact with notches 41 of aperture 60 in coupling member 50to couple coupling member 50 to upper housing 38. Longitudinal extension29 extends through opening 53 in coupling number 50 into aperture 64 incarrier 62. Projections 65 extend into depressions 69 in the uppersurface of upper disc 68. As discussed above, the diameters of carrier62 and upper disc 68 are substantially smaller than the diameter oflower disc 72.

As further shown in FIG. 10, carrier 62 and upper disc 68 aretranslationally moved by longitudinal extension 29 of stem assembly 23in different directions (e.g., orthogonal) to selectively adjust thetemperature and the flowrate of water supplied by valve assembly 24. Asdiscussed above, one of the seals 90 c is positioned in outlet bore 95of valve body 34. Outlet bore 95 opens into radially extending outletbore 36 in valve body 34. As detailed herein, seal 90 c directlycontacts the lower surface of lower disc 72 around outlet port 78.Outlet bore 36 is also in communication with axially extending outletbore 92 of valve body 34. Bore 92 may be coupled to spout 16 or to anaccessory supply line which may be used for a hand sprayer or any othersuitable fluid delivery device.

Referring now to FIGS. 10-12, valve assembly 24 is shown with stem 26pivoted or oriented to place the internal components of valve assembly24 in the partially open position. When stem 26 is in this orientation,an equal amount of hot and cold water is allowed to pass through hot andcold water inlets 76 a and 76 b to outlet port 78. Referringspecifically to FIGS. 11 and 12, in this orientation, channel 77 and thelower surface 68 b of upper disc 68 are positioned over a small portionof each of the hot and cold water inlet ports 76 a and 76 b. In otherwords, the inner channel edge 73 a partially overlaps the outer controledges 85 of the inlet ports 76 a and 76 b. Central portion 73 of upperdisc 68 is covering a significant portion of inlet ports 76 a and 76 b.As water enters channel 77 through inlet hot and cold water inlet ports76 a and 76 b, it fills channel 77, mixes to create “warm” water, andexits through outlet 78, which is substantially open to channel 77. The“warm” water then moves through outlet port 78 and seal 90 to outletbore 95 and spout 16 as shown in FIG. 1.

Referring now to FIGS. 13-15, stem 26 has been pivoted forward to adifferent orientation such that inlet ports 76 a and 76 b aresubstantially uncovered or unblocked by central portion 73 of upper disc68. In other words, there is a substantial overlap between the innerchannel edge 73 a and the outer control edges 85 of the inlet ports 76 aand 76 b. A greater amount of hot and cold water is allowed to fillchannel 77, mix to create “warm” water, and exit through outlet port 78.The water then exits valve assembly 24 through outlet bore 95 asdiscussed above. In each of these two positions, hot water and coldwater from inlet ports 76 a and 76 b are mixed in channel 77 to producedwarm water, which will exit channel 77 through outlet port 78. In theembodiment shown in FIGS. 10-12, a lower flowrate or amount of waterwill exit valve assembly 24. In FIGS. 13-15, a “full flow,” or maximumflowrate of water, will exit valve assembly 24.

Referring now to FIGS. 16-18, stem 26 is shown pivoted in a rearwarddirection to the fully or completely closed orientation. In thisorientation, valve assembly 24 will be closed (i.e., no water will flowthrough valve assembly 24). Scallop or convergence 46 a of aperture 46(FIG. 2) cooperates with longitudinal extension 29 of stem assembly 23to provide a detent of stem assembly 23 when in the completely closed orzero position. As shown in FIGS. 16 and 18, central portion 73 of upperdisc 68 completely covers or blocks hot and cold water inlet ports 76 aand 76 b to prevent water from filling channel 77 and exiting throughoutlet port 78. Even if water were to leak through either inlet ports 76a and 76 b to channel 77, the water would exit channel 77 through outlet78 to create a drip or small stream, for example, through the spout ofthe faucet assembly including valve assembly 24. In this manner, channel77 prevents water leaks in the valve assembly 24 from leaking throughthe valve assembly to the faucet base 12 or under the faucet 10, whichmay cause corrosion around the faucet base 12 or handle 14 of the faucet10. If any leakage were to occur in valve assembly 24 as a result ofdamage to discs 68 and 72 adjacent ports 76 a, 76 b, 78, the waterleaked would exit valve assembly 24 through outlet bore 95 and anyattached spout 16 or accessory rather than around the base 12 of thefaucet 10.

FIGS. 19 and 20 illustrate the stem 26 orientation and the correspondingposition of upper disc 68 when the operator desires only cold water fromvalve assembly 24. As shown, when stem 26 is positioned in thisorientation, central portion 73 of upper disc 68 completely covers orblocks hot water inlet port 76 a and completely uncovers or unblocks thecold water inlet port 76 b, allowing the water from the uncovered port76 b to flow through channel 77 to outlet port 78. Conversely, in FIGS.22 and 23, the stem 26 orientation shown opens the opposite port 76 a(i.e., allows the user to select completely hot water flow). As shown,in this orientation, central portion 73 of upper disc 68 completelycovers or blocks the previously uncovered cold water inlet port 76 b andcompletely opens the previously covered hot water inlet port 76 a toallow hot water to fill channel 77 and exit through outlet port 78. Inother words, movement of the upper disc 68 relative to the lower disc 72in a direction from the hot water inlet port 76 a to the cold waterinlet port 76 b causes an increase in water flow through the hot waterinlet port 76 a. while movement of the upper disc 68 relative to thelower disc 72 in a direction from the cold water inlet port 76 b to thehot water inlet port 76 a causes an increase in water flow through thecold water inlet port 76 b.

Another illustrative embodiment of valve assembly 24 is shown in FIGS.23-26. Referring now to FIGS. 23 and 24, valve assembly 110 includesbonnet nut 112, upper housing 116, stem assembly 120, coupling member130, carrier 132, upper disc 138, lower disc 144, upper seal 150, lowerhousing 152, lower seal 154, and valve body 158. Valve assembly 110 issimilar to valve assembly 24 shown in the previous embodiment, howevervalve assembly 110 includes two opposing sealing surfaces instead of thesingle sealing surface defined by seals 90 in valve assembly 24. In thisembodiment, carrier 132 includes interior wall 134 and downwardextending projection 136, which interacts with notch 142 in upper disc138. Upper disc 138 also includes opening 140 which is configured toaccept interior wall 134 of carrier 132. Longitudinal extension 129 ofstem assembly 120 extends through coupling member 130 and into interiorwall 134 of carrier 132 to actuate carrier 132 and upper disc 138.

Referring now to FIGS. 25 and 26, lower disc 144 includes hot and coldwater inlet ports 146 a and 146 b and outlet port 148. The lower surfaceof lower disc 144 includes channel 145 extending around inlet ports 146a and 146 b and outlet port 148. Seal 150 is positioned in channel 145and corresponds to channel 151 in the upper surface of lower housing 152as shown in FIG. 26. The lower housing 152 includes channel 153extending around inlet apertures 151 and outlet aperture 155. Channel153 corresponds to seal 154 which is positioned in channel 153 toprovide a seal against the interior lower surface of valve body 158.Valve body 158 includes inlet bores 160 and outlet bore 162 which areconfigured to couple to hot and cold water inlet supply lines and anoutlet supply line. In this embodiment, valve assembly 110 includes twosealing surfaces 150 and 154 compared to the single layer of sealingsurfaces formed by seals 90 between lower disc 72 and the interior lowersurface of valve body 34 of valve assembly 24 shown in FIGS. 2-22.

A further illustrative embodiment valve assembly 210 is shown in FIGS.27-38D. While not shown, bonnet nut 28 and valve body 34 similar tothose detailed above may be utilized to receive the internal valvecomponents of valve assembly 210. Valve assembly 210 includes upperhousing 216, temperature limiting member 218, stem assembly 220,coupling member 230, carrier 232, upper disc 238, lower disc 244, upperseal 250, lower housing 252, and lower seal 254. Carrier 232, upper disc238, and lower disc 244, may be similar to carrier 132, upper disc 138,and lower disc 144, as detailed above. Likewise, seals 250 and 254 maybe similar to seals 150 and 154, as detailed above in connection withvalve assembly 110.

Furthermore, as with valve assembly 110, upper disc 238 may includeopening 140 which is configured to receive interior wall 134 of carrier232. Also, lower disc 244 includes hot and cold water inlet ports 146 aand 146 b and outlet port 148.

As shown in FIG. 28, stem assembly 220 includes a ball 225 whichreceives a stem 226. As shown in FIGS. 28 and 31, stem 226 may besubstantially L-shaped and include upwardly extending leg 228 a andlaterally extending leg 228 b. Ball 225 may be molded from athermoplastic material over a portion of stem 226, such that leg 228 bdefines a support for a lateral extension 227. A longitudinal extensionor knuckle 229 extends downwardly from the ball 225 generally oppositeleg 228 a of the stem 226. In a manner similar to that detailed above,ball 225 transmits motion of stem 226 to upper disc 238 throughextension 229 and carrier 232.

With reference to FIGS. 28 and 32, coupling member 230 includesdiametrically opposed tabs 256 extending downwardly from a circular base258. Tabs 256 are configured to be received within notches 260 formedwithin lower housing 252 to facilitate proper angular orientationbetween coupling member 230 and lower housing 252 and prevent relativerotation therebetween. A pair of diametrically opposed notches 262 areformed within an outer edge of base 258 and are configured to receivelocking extensions or loops 264 of upper housing 216. A pair ofdiametrically opposed recesses 266 extend downwardly from an uppersurface 268 of base 258 and are configured to receive tabs 270 of upperhousing 216, thereby facilitating proper angular orientation betweenupper housing 216 and coupling member 230. An upwardly extendingcylindrical wall 272 is coupled to base 258 and forms a cavity 274having an arcuate surface 276. An opening 278 formed within wall 272 isconfigured to receive extension 227 of stem assembly 220. Ball 225 ofstem assembly 220 is configured to contact arcuate surface 276 ofcoupling member 230 in a manner similar to that detailed above withrespect to valve assembly 24. Aperture 280 is positioned at the bottomof cavity 224 and is configured to receive extension 229 of stemassembly 220 which, in turn, engages carrier 232.

With reference to FIGS. 28 and 34, temperature limiting member 218 isreceived intermediate coupling member 230 and upper housing 216.Temperature limiting member 218 includes a cylindrical body portion 282and a pair of downwardly extending biasing members, illustrativelyflexible arms 284. The flexible arms 284 have a lower contact surface286 configured to slide along a glide surface defined by the uppersurface 268 of base 258 of coupling member 230. Body portion 282includes a cylindrical wall 286 having an upper surface 288 supporting aplurality of indexing members, illustratively teeth 290. An indicator292 extends upwardly above the teeth 290. Wall 286 of cylindrical bodyportion 282 includes a downwardly facing inclined surface 294. Asexplained herein, inclined surface 294 cooperates with lateral extension227 of stem assembly 220 to limit the lateral pivoting motion of stem226 and extension 229 (i.e., relative to inlet ports 146 a and 146 b),and hence the maximum allowable temperature of water flowing through thevalve assembly 210.

Referring now to FIGS. 28, 29, 31, and 33, upper housing 216 includes acylindrical outer wall 296 and a cylindrical inner wall 298. Walls 296and 298 are concentric, thereby defining a channel 300 therebetween. Anupper portion of wall 286 of temperature limiting member 218 issupported for movement within channel 300. A rim 302 extends radiallyoutwardly from outer wall 296. Downwardly extending loops 264 aresupported by rim 302 and are configured to cooperate with notches 262formed in the coupling member 230, and with latches or tabs 304 formedwithin lower housing 252 (FIG. 28). More particularly, the loops 264 arereceived within recesses 306 surrounding the latches 304. Each latch 304includes an inclined or ramp surface 308 and a retaining surface 310configured to cooperate with an inner surface 312 of the respective loop264. Outer wall 296 includes a receiving channel or slot 314 configuredto receive the lateral extension 227 of the stem assembly 220.

As shown in FIGS. 31 and 33, a plurality of indexing members,illustratively teeth 316, extend downwardly from an upper member 318 ofupper housing 216 and are configured to cooperate with teeth 290 oftemperature limit device 218. An arcuate slot 320 is formed within uppermember 318 of upper housing 216 and is configured to receive indicator292. An opening 322 similar to opening 46 of previously described upperhousing member 38 is formed within upper member 318.

Pivoting movement of stem assembly 220 about axis 324 of lateralextension 227 controls the flow rate of water, while pivoting movementof stem assembly 220 about an axis 326, perpendicular to axis 324 oflateral extension 227 and stem 226, controls the temperature of watersupplied by valve assembly 210. The inclined surface 294 of thetemperature limiting member 218 controls the amount of pivoting movementof the stem assembly 220 about axis 326. As further detailed below,rotation of the temperature limiting member 218 about its center axis328 limits the motion permitted of stem assembly 220 about axis 328.

As detailed herein, stem assembly 220 includes ball 225 that transmitsstem motion to upper disc 238 through extension 229. Ball 225 allowsspherical rotation, while preventing lateral motion. Since valveassembly 210 only requires two degrees of freedom (temperature andvolume), rotation about stem assembly 220 is prevented by operation oflateral extension 227 coupled to ball 225 that rides in the slot 314 incooperating upper housing 216.

Lateral extension 227 has two motions in slot 314. The first motion is apivot motion about its own axis 324. The second motion is a pivot motionabout axis 326, which is substantially vertical, within slot 314, andwhich has a constant radius from the center of the ball 225. Throughorientation of slot 314, these two motions may correspond directly totemperature and volume motion of valve disc 218.

While the pivoting movement of stem assembly 220 of valve assembly 210is similar to the pivoting movement of stem assembly 120 of valveassembly 110 (FIG. 23), the extension 227 of stem assembly 220 is offsetby 90° from extensions 27 of stem assembly 120. If the extension 227 islocated in a side-to-side orientation relative to inlet ports 146 a and146 b (FIG. 28), as opposed to a front-to-back orientation relative toinlet ports 146 a and 146 b and outlet port 148 (FIG. 23), thetemperature will be directly related to the motion of the extension 227in the slot 314. The flow rate control motion will translate to therotation of the extension 227 about its own axis 324. As such, to limitthe maximum temperature, the travel of extension 227 within the slot 314is reduced or limited. The limiting member 218 includes inclined surface294 that engages extension 227 on the ball 225. As the temperaturelimiting member 218 is rotated about axis 328 of the valve assembly 210,the point of inclined surface 294 that is engageable with the extension227 is set at different heights and, thereby, limits the travel of theextension 227 in the slot 314. This, in turn, limits the motion of upperdisc 238 relative to lower disc 244, including hot water inlet put 146a.

Teeth 290 of temperature limiting member 218 engage with correspondingteeth 316 on the upper housing 216. This engagement keeps thetemperature limit device 218 from slipping under load and providesdetents to indicate discrete adjustment positions. Flex arms 284 oftemperature limiting member 218 provide a preload on the engaged teeth290, 316 and to prevent temperature limiting member 218 from slippingdue to vibration. This preload also gives the adjuster a tactilefeedback to prevent over-correction of a temperature limiting member218. The tab or indicator 292 of the temperature limiting member 218also protrudes through the slot 320 of upper housing 216 and provides avisual indication to the user of the temperature setting. Marks may beprovided on the upper housing 216 to provide reference points of therelative position of indicator 292 within slot 320.

With further reference now to FIGS. 29, 30, and 35A-35C, valve assembly210 is illustrated with the temperature limiting member 218 positionedin a low limit position “L”. Indicator 292 in FIG. 29 shows the lowlimit position within slot 320 of upper housing 216. In FIGS. 29, 30,and 35A, stem assembly 220 is in a fully-closed position. As detailedabove, this means that the upper disc 238 engages the lower disc 244 sothat water does not flow from either hot or cold inlet ports 146 a and146 b to outlet port 148. As shown in FIG. 35B, valve assembly 220 ismoved to an open hot limit position. Moreover, stem assembly 220 ispivoted about axis 324 to an open flow position and also pivoted aboutaxis 326 to the temperature limit position as defined by the inclinedsurface 294 of temperature limiting device 218. In other words, stemassembly 220 is pivoted as far as possible to its hot, or left, positionabout axis 326 due to engagement of the extension 227 and inclinedsurface 294 of temperature limiting member 218. FIG. 35C illustrates thevalve assembly 210 in an open cold limit position, where the valveassembly 220 is pivoted as far as possible to its cold, or right,position about axis 326 due to engagement between the extension 227 andbase 258.

FIGS. 36-38D show valve assembly 210 with temperature limiting member218 in a high limit position “H”. Indicator 292 in FIG. 36 shows thehigh limit position within slot 320 of upper housing 216. In otherwords, temperature limiting member 218 has been rotatedcounter-clockwise by approximately 90 degrees from the position shown inFIGS. 29, 30, and 35A-35C. Such rotation is accomplished by pushing downon temperature limiting member 218 against the bias of arms 284, suchthat teeth 290 disengage from teeth 316 of upper housing 216.Temperature limiting member 218 is then free to be rotated by glidingsurfaces 286 of arms 284 against slide surface 268 of coupling member230, such that indicator 292 moves within arcuate slot 320.

FIGS. 36-38A illustrate stem assembly 220 in a fully-closed position.FIG. 38B shows stem assembly 220 in a mixed temperature position wherewater flows from both hot and cold inlet ports 146 a and 146 b to outletport 148 of upper disc 244. FIG. 38C illustrates stem assembly 220 in anopen hot limit position where maximum flow is permitted through hotwater port to outlet 148. As clearly illustrated by comparing FIG. 38Cto FIG. 35B, the stem in FIG. 38C has rotated further about axis 326toward the hot water position, or to the left. This is because the pointof contact between extension 227 and inclined surface 294 is higher inFIG. 38C than in FIG. 35B. As detailed above, in FIGS. 36-38Dtemperature limiting member 218 has been rotated counter-clockwiseapproximately 90° from the position shown in FIGS. 29, 30, and 35A-35C.FIG. 38D illustrates stem assembly 220 in an open cold limit positionwhich is substantially the same as that position illustrated in FIG.35C.

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe spirit and scope of the invention as described and defined in thefollowing claims.

1. A valve assembly for controlling water flow in a faucet, the valveassembly including: a valve body including hot and cold water inlets andan outlet; a lower disc including first, second, and third portscorresponding to the hot and cold water inlets and the outlet, the lowerdisc supported by the valve body; an upper disc including upper andlower surfaces, the lower surface positioned in engagement with thelower disc and including an inner channel edge and an outer channel edgedefining a closed peripheral channel for selective communication withthe first, second, and third ports, the closed peripheral channelextending around a center portion of the lower surface and configured tomix hot water from the first port and cold water from the second portbefore reaching the third port, the center portion of the lower surfaceconfigured to selectively seal the first port and the second port fromthe third port; and a stem operably coupled to the upper disc andsupported for pivoting movement about orthogonal axes extending within aplane parallel to the upper disc; wherein translational movement of theupper disc in a first direction moves the inner channel edge to changewater flow rate through the third port, translational movement of theupper disc in a second direction perpendicular to the first directionmoves the inner channel edge to change the proportion of water flowthrough the first and second ports, and translational movement in thefirst direction from the third port toward the first and second portsmoves the center portion to close the first and second ports.
 2. Thevalve assembly of claim 1, wherein at least one of the upper and lowerdiscs is constructed of a metallic material.
 3. The valve assembly ofclaim 1, wherein at least one of the upper and lower discs isconstructed of a ceramic material.
 4. The valve assembly of claim 1,wherein the upper and lower discs each define a substantially circularperimeter and the channel extends adjacent the circular perimeter. 5.The valve assembly of claim 4, wherein the channel includes a V-shapedportion.
 6. The valve assembly of claim 1, wherein the upper discincludes an aperture extending therethrough.
 7. The valve assembly ofclaim 1, wherein the channel extends circumferentially around the lowersurface of the upper disc.
 8. The valve assembly of claim 1, wherein thelower surface of the upper disc includes a central projection extendingoutwardly.
 9. The valve assembly of claim 1, wherein the lower surfaceof the upper disc includes a center sealing portion configured tocooperate with the lower disc to form the channel.
 10. The valveassembly of claim 1, wherein the lower surface of the upper discincludes an outer annular wall and a central portion that defines thechannel, the central portion extending between the hot and cold waterinlets.
 11. The valve assembly of claim 1, further comprising: atemperature limiting member including an engagement surface configuredto set a hot water limit for limiting movement of the stem assembly andthe flow of hot water through the lower disc.
 12. The valve assembly ofclaim 11, wherein the temperature limiting member is adjustable tochange the position of the engagement surface relative to the stemassembly and thereby adjust the hot water limit.
 13. The valve assemblyof claim 11, wherein the temperature limiting member includes indexingmembers for setting the hot water limit.
 14. The valve assembly of claim1, wherein translational movement of the upper disc relative to thelower disc in a direction from the first port to the second port causesan increase in hot water flow through the first port, and translationalmovement of the upper disc relative to the lower disc in a directionfrom the second port to the first port causes an increase in cold waterflow through the second port.
 15. The valve assembly of claim 1, whereinmovement of the stem in a first direction causes movement of the upperdisc in a second direction opposite the first direction.
 16. The valveassembly of claim 15, wherein movement of the stem in a direction towardthe first port causes the upper disc to uncover the first port, andmovement of the stem in a direction toward the second port causes theupper disc to uncover the second port.
 17. The valve assembly of claim16, further comprising a ball supported above the upper disc, and aknuckle extending downwardly from the ball, wherein the stem extendsupwardly from the ball.
 18. A valve assembly for controlling water flowin a faucet, the valve assembly including: a valve body including hotand cold water inlets and an outlet; a lower disc including first,second, and third ports corresponding to the hot and cold water inletsand the outlet, the lower disc supported by the valve body; an upperdisc including upper and lower surfaces, the lower surface positioned inengagement with the lower disc and including an inner channel edge andan outer channel edge defining a closed peripheral channel for selectivecommunication with the first, second, and third ports, the closedperipheral channel extending around a center portion of the lowersurface and configured to mix hot water from the first port and coldwater from the second port before reaching the third port, the centerportion of the lower surface configured to selectively seal the firstport and the second port from the third port; and a stem assemblyincluding a ball supported for pivoting movement about a first axis anda second axis orthogonal to the first axis, a stem extending upwardlyfrom the ball, and a knuckle extending downwardly from the ball andoperably coupled to the upper disc; the stem assembly supported forpivoting movement about the first axis to cause the inner channel edgeof the upper disc to move linearly in a first direction to change waterflow rate through the third port, and supported for pivoting movementabout the second axis to cause the inner channel edge of the upper discto move linearly in a second direction perpendicular to the firstdirection to change the proportion of water flow through the first andsecond ports, wherein translational movement in the first direction fromthe third port toward the first and second ports moves the centerportion to close the first and second ports.
 19. The valve assembly ofclaim 18, wherein movement of the stem in a first direction causesmovement of the upper disc in a second direction opposite the firstdirection.
 20. The valve assembly of claim 18, wherein movement of thestem in a direction toward the first port causes the upper disc touncover the first port, and movement of the stem in a direction towardthe second port causes the upper disc to uncover the second port. 21.The valve assembly of claim 18, wherein at least one of the upper andlower discs is constructed of a metallic material.
 22. The valveassembly of claim 18, wherein at least one of the upper and lower discsis constructed of a ceramic material.
 23. The valve assembly of claim18, wherein the upper and lower discs each define a substantiallycircular perimeter and the channel extends adjacent the circularperimeter.
 24. The valve assembly of claim 23, wherein the channelincludes a V-shaped portion.
 25. The valve assembly of claim 18, whereinthe upper disc includes an aperture extending therethrough.
 26. Thevalve assembly of claim 18, wherein the channel extendscircumferentially around the lower surface of the upper disc.
 27. Thevalve assembly of claim 18, wherein the lower surface of the upper discincludes a central projection extending outwardly.
 28. The valveassembly of claim 18, wherein the lower surface of the upper discincludes a center sealing portion configured to cooperate with the lowerdisc to form the channel.
 29. The valve assembly of claim 18, whereinthe lower surface of the upper disc includes an outer annular wall and acentral portion that defines the channel, the central portion extendingbetween the hot and cold water inlets.
 30. The valve assembly of claim18, further comprising: a temperature limiting member including anengagement surface configured to set a hot water limit for limitingmovement of the stem assembly and the flow of hot water through thelower disc.
 31. The valve assembly of claim 30, wherein the temperaturelimiting member is adjustable to change the position of the engagementsurface relative to the stem assembly and thereby adjust the hot waterlimit.
 32. The valve assembly of claim 30, wherein the temperaturelimiting member includes indexing members for setting the hot waterlimit.